Solenoid coil having an enhanced magnetic field

Abstract

An improved solenoid having an enhanced magnetic field and failsafe operation is provided, wherein a primary winding and a secondary winding are constructed such that the combined force imparted on a plunger by both windings energized together is greater than the sum of the forces imparted by the primary and secondary windings energized separately, resulting in a smaller solenoid capable of providing a predetermined force, and providing a solenoid capable of tripping a circuit interrupting latch even if one of the windings is broken.

What is claimed is: 
     
       1. A solenoid comprising:
 a bobbin having a hollow center with a plunger therein; 
 a primary winding including 34 AWG wire, the primary winding having a starting end and a terminating end, wound on said bobbin and imparting a first magnetic force on said plunger when said primary winding is electrically energized, the first magnetic force being greater than a predetermined force; and 
 a secondary winding including 33 AWG wire, the secondary winding having a starting end and a terminating end, wound on top of said primary winding and imparting a second magnetic force on said plunger when said secondary winding is electrically energized, the second magnetic force being greater than the predetermined force; 
 wherein said primary winding and said secondary winding are configured to be in a first state, a second state, and a third state, wherein when in the first state the primary winding is energized and the secondary winding is not energized, wherein when in the second state said secondary winding is energized and said primary winding is not energized, and wherein when in the third state said primary and secondary windings are energized together, wherein when said primary and secondary windings are energized together, a third magnetic force is imparted on said plunger that is greater than the combination of said first and second magnetic forces, wherein the third magnetic force is at least 40% greater than the combination of the first and second magnetic forces; 
 wherein a second layer is wound on top of a first layer, said first layer including of a first portion of said primary winding and said second layer including a second portion of said primary winding and a first portion of said secondary winding. 
 
     
     
       2. The solenoid of  claim 1 , wherein the predetermined force is sufficient to trip a circuit interrupting latch of a ground fault circuit interrupter. 
     
     
       3. The solenoid of  claim 1 , wherein the predetermined force is between 1.5 and 1.6 lbs. 
     
     
       4. The solenoid of  claim 1 , wherein the predetermined force is between 1.35 and 1.5 lbs. 
     
     
       5. The solenoid of  claim 1 , wherein the predetermined force is greater than 4.4 lbs. 
     
     
       6. A method of forming a solenoid comprising a bobbin having a hollow center with a plunger therein comprising the steps of
 winding a primary winding onto said bobbin, the primary winding including 34 AWG wire and being sufficient to impart a first magnetic force on said plunger when said primary winding is electrically energized, the first magnetic force being greater than a predetermined force; and 
 winding a secondary winding on top of said primary winding, the secondary winding including 33 AWG wire and being sufficient to impart a second magnetic force on said plunger when said secondary winding is electrically energized, the second magnetic force being greater than the predetermined force; 
 wherein said primary winding and secondary windings are configured to be in a first state, a second state, and a third state, wherein when in the first state the primary winding is energized and the secondary winding is not energized, wherein when in the second state said secondary winding is energized and said primary winding is not energized, and wherein when in the third state said primary and secondary windings are energized together, wherein when said primary and secondary windings are energized together, a third magnetic force is imparted on said plunger that is greater than the combination of said first and second magnetic forces, wherein the third magnetic force is at least 40% greater than the combination of the first and second magnetic forces; 
 wherein a second layer is wound on top of a first layer, said first layer including of a first portion of said primary winding and said second layer including a second portion of said primary winding and a first portion of said secondary winding. 
 
     
     
       7. The method of  claim 6 , wherein said first gauge has a smaller diameter than said second gauge. 
     
     
       8. The method of  claim 6 , wherein the predetermined force is sufficient to trip a circuit interrupting latch of a ground fault circuit interrupter. 
     
     
       9. A method of operating a solenoid comprising a bobbin having a hollow center with a plunger therein comprising the steps of
 winding a primary winding onto said bobbin, the primary winding including 34 AWG wire and being sufficient to impart a first magnetic force on said plunger when said primary winding is individually electrically energized in a first state, the first magnetic force being greater than a predetermined force; 
 winding a secondary winding on top of said primary winding, the secondary winding including 33 AWG wire and being sufficient to impart a second magnetic force on said plunger when said secondary winding is individually electrically energized in a second state, the second magnetic force being greater than the predetermined force; and 
 energizing the primary and secondary windings together when the primary and secondary windings are each unbroken in a third state, thereby imparting a third magnetic force on said plunger, the third magnetic force being greater than the combination of said first and second magnetic forces; and 
 if said secondary winding is broken, energizing said primary winding in the first state and not energizing said secondary winding, to impart said first magnetic force on said plunger and if said primary winding is broken, energizing said secondary winding in the second state and not energizing said primary winding, to impart said second magnetic force on said plunger, wherein the third magnetic force is at least 40% greater than the combination of the first and second magnetic forces; 
 wherein a second layer is wound on top of a first layer, said first layer including of a first portion of said primary winding and said second layer including a second portion of said primary winding and a first portion of said secondary winding. 
 
     
     
       10. The method of  claim 9 , wherein the predetermined force is sufficient to trip a circuit interrupting latch of a ground fault circuit interrupter. 
     
     
       11. The method of  claim 9 , wherein the first magnetic force is between 1.35 and 1.5 lbs.